Key Takeaways
- Seal Selection: Use Silicon Carbide seal faces for glycol mixtures exceeding 30% concentration to prevent premature failures
- Preventive Maintenance: Install filters with flow indicators in seal flush lines to trap sediment and extend pump life
- Installation Best Practices: Vertical inline pumps can be fully pipe-supported without bases or isolators, saving installation costs
- Critical Start-up Step: Remove fine mesh strainers after 24 hours of operation to prevent cavitation and seal damage
Armstrong Fluid Technology: 15 Essential Hydronic System Tips
Armstrong stands as the world leader in fluid technology, and when it comes to hydronic systems, they’re second to none. These field-proven tips from Armstrong’s engineering team will help you maintain, troubleshoot, and optimize hydronic pumping systems. For additional resources, visit Armstrong Fluid Technology.
Pump Seal and Bearing Maintenance
Tip #1: Selecting the Right Mechanical Seal for Glycol Systems
When replacing a mechanical seal, always verify the system fluid composition first. For glycol mixtures exceeding 30% concentration by volume, Silicon Carbide is required for both seal faces. This material selection is critical for preventing premature seal failure in glycol-based systems.
Tip #2: Implementing Seal Protection Strategies
If pump seal failures occur frequently, consider installing a filter with a flow indicator in the seal flush lines. This filter will capture sediment that may be causing premature seal failures. Ensure operators regularly check the flow indicator and replace the filter when seal flow decreases.
For pumps with differential pressures above 30 psig (measured between inlet and outlet pressure gauges), you can use a sediment separator instead, which eliminates the need for constant monitoring.
Tip #3: Retrofitting Older Armstrong S&H Circulators
Don’t automatically replace an older Armstrong S&H circulator with a new unit. You can effectively service it using the Armstrong Seal Bearing Assembly (SBA). This universal seal bearing assembly contains an interchangeable module that includes:
- Pump shaft
- Sleeve bearing
- Copper sleeve
- Donut wicking system
With just five types of seal bearing assemblies, you can convert more than 100 different Armstrong and B&G pump models to this modular program during routine maintenance. Once converted, future maintenance typically requires only module replacement.
Installation and Alignment Guidelines
Tip #4: Simplifying Vertical Inline Pump Installation
Armstrong vertical inline pumps can be fully supported by the piping system without requiring:
- Base plates
- Inertia pads
- Springs or rubber isolators
- Pump stands
This design feature saves both labor costs and installation time while maintaining proper pump support.
Tip #5: Understanding Coupling Alignment Requirements
Horizontal pumps with flexible couplings require on-site shaft realignment between pump and motor prior to start-up, as misalignment can occur during shipment. However, vertical and horizontal split-coupled pumps with rigid aluminum couplings maintain their factory alignment and don’t need field realignment.
Tip #6: Avoiding Motor Support Problems
If you observe horizontal circulators with supports under the motor, flag this as a problem immediately. Propping up the motor from below or suspending it from above causes misalignment that leads to bearing or seal failure. The pump and motor should be properly aligned and supported as a unit.
Advanced Control and Configuration Options
Tip #7: Leveraging Design Envelope Pump Controls
When you need to adjust flow rates in commercial pumps, Design Envelope pumps offer immediate on-site control access. These pumps display actual system flow and head directly at the pump interface. The latest Generation 5 models feature Wi-Fi connectivity, allowing control via smartphone or tablet—particularly convenient when pumps are installed in high or difficult-to-access locations. This technology integration aligns with modern BMS control fundamentals that technicians increasingly encounter in commercial buildings.
Tip #8: Maximizing Flow with Dual-Head Pumps
When additional flow is needed but space constraints prevent adding another pump and piping, consider dual-head pumps. These units feature two pump rotating assemblies within a single casing design operating in one pipe. The pump heads can operate:
- Individually for standard flow
- Together for doubled flow capacity
- With integrated controls that optimize efficiency by bringing the second unit online as needed, reducing power costs
Equipment Identification and Documentation
Tip #9: Preserving Equipment Nameplates
Never remove equipment nameplates from pumps. While this may have been common practice in the past, modern cell phones provide a better solution for capturing data. You can photograph the nameplate and instantly transfer the image to service personnel to confirm pump identification and spare parts requirements.
Tip #10: Alternative Equipment Identification
If you cannot locate the equipment nameplate, check the volute itself—pump information is often stamped directly on the volute casting.
Expansion Tank Installation and Setup
Tip #11: Horizontal Tank Mounting Guidelines
Bladder expansion tanks and AX series diaphragm tanks can be mounted horizontally using saddles positioned under the weld seams. If the system connection is off-center, rotate the tank so the system connection sits above the centerline for proper operation.
Tip #12: Setting Proper Air Charge Pressure
The air charge on bladder or diaphragm tanks should be set 2-5 psi above the cold fill system pressure. Apply this air charge before connecting the tank to the system to ensure proper operation and prevent bladder damage.
Tip #13: Seismic Requirements for Vertical Tanks
Due to increased seismic activity across North America, some jurisdictions now require seismic clips on the base ring of vertically mounted expansion tanks. Check local codes for specific requirements in your area.
Heat Exchanger and System Start-up Procedures
Tip #14: Ensuring Proper Heat Exchanger Flow
To maximize plate and frame heat exchanger efficiency, verify that system connections are configured for countercurrent flow. The two inlet connections should be on opposite corners from each other. The outlet will always be positioned above or below the inlet—never beside it. This configuration ensures maximum heat transfer efficiency.
Tip #15: Critical Start-up Strainer Removal
When commissioning a new system, shut down after 24 hours of operation to open the suction guide and remove the fine mesh start-up strainer from the steel basket strainer. Continued operation with the mesh filter in place will eventually starve the pump of suction pressure, causing cavitation and seal damage. This critical step is often overlooked but essential for long-term pump reliability.
Maximizing Your Service Efficiency
These Armstrong tips represent decades of field experience and engineering expertise. Proper implementation of these guidelines will help prevent common failures and extend equipment life. For technicians looking to expand their troubleshooting capabilities, understanding proper belt replacement procedures and seasonal maintenance scheduling can complement your hydronic system expertise.
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Stay tuned for tips 16-30 in our next installment, where we’ll cover advanced troubleshooting techniques, system optimization strategies, and energy-saving modifications for Armstrong hydronic systems.
